Solid electrolytes with novel electrolyte salts and electrolytic cells produced therefrom

ABSTRACT

Solid electrolytes containing a novel electrolyte salt which has the combined functions of both inorganic salt and electrolytic solvent are provided. The novel electrolyte has the structure: ##STR1## where A is either ##STR2## where Z is oxygen, --O--, sulfide --SH 2  --, or amine ##STR3## is 1 to about 10; where R&#39; is selected from the group consisting of an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about carbon atoms, and wherein n is independently an integer from 1 to about 5 and R is independently selected from the group consisting of hydrogen, an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms.

BACKGROUND OF THE INVENTION

1. Field Of the Invention

This invention is directed to solid electrolytes containing a polymer matrix and a novel electrolyte salt. The novel electrolyte salt has an anion portion which functions as a counter ion to a metal ion. The novel electrolyte salt can partially or completely replace the inorganic ion salt and/or electrolytic solvent used in conventional solid electrolytes.

2. State of the Art

Electrolytic cells containing an anode, a cathode and a solid, solvent-containing electrolyte are known in the art and are usually referred to as "solid batteries." See, instance, U.S. Pat. Nos. 5,229,225, 5,238,758, 5,358,801, and 5,366,829. These cells offer a number of advantages over electrolytic cells containing a liquid electrolyte (i.e., "liquid batteries") including improved safety features.

For electrolytic cells, the inorganic ion salts typically have a transference number between 0.4 and 0.55, meaning that the ion salt carries only between 40% and 55% of the total plus (+) charge. The relatively low transference number also adversely affects cumulative capacity. The cumulative capacity of a solid battery is defined as the summation of the capacity of the battery over each cycle (charge and discharge) in a specified cycle life.

Another problem with current electrochemical cells relates to solvent volatility. In a typical solid electrolytic cell, the solid electrolyte contains a solvent (plasticizer) which is added to the polymeric matrix primarily to enhance the solubility of the inorganic ion salt in the solid electrolyte and thereby increase the conductivity of the electrolytic cell. Unfortunately, a significant quantity of solvent evaporates during processing to form the solid electrolyte. To retain sufficient solvent in the final product therefore requires a higher initial amount of solvent in the electrolyte formulation. This increases both raw material and processing costs since the evaporated solvent must either be recaptured, recycled or disposed of.

In view of the above, the art is searching for methods to improve the conductivity of solid electrolytes and the cumulative capacity of solid batteries employing such solid electrolytes. Furthermore, there is a need in the art for reducing or eliminating problems associated with solvent volatility.

SUMMARY OF THE INVENTION

The present invention is directed, in part, to the use of novel electrolyte salts in solid electrolytes that results in improved conductivity and cumulative capacity in electro-chemical cells made therefrom. In essence, the novel electrolyte salt combines the function of the inorganic salt and electrolytic solvent of conventional solid electrolytes. The novel electrolyte salt is expected to be less volatile compared to conventional solvents.

Accordingly, in one of its composition aspects, this invention is directed to a solid electrolyte which comprises:

a solid polymeric matrix; and

an effective amount of an electrolyte salt having the following structure: ##STR4## where A is either ##STR5## where Z is oxygen, --O--, sulfide --SH₂ --, or amine ##STR6## x is 1 to about 10; where R' is selected from the group consisting of an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about carbon atoms, and wherein n is independently an integer from 1 to about 5 and R is independently selected from the group consisting of hydrogen, an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms.

In another of its composition aspects, the present invention is directed to an electrolytic cell which comprises:

an anode;

a cathode; and interposed therebetween a solid electrolyte which comprises:

a solid polymeric matrix; and

an effective amount of the electrolyte salt as defined above.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As noted above, this invention is directed to solid electrolytes which, by virtue of the novel electrolyte salt employed, provide for increased ion conductance and cumulative capacity in electrochemical cells. However, prior to describing this invention in further detail, the following terms will first be defined.

Definitions

As used herein, the following terms have the following meanings.

The term "solid polymeric matrix" refers to an electrolyte compatible material formed by polymerizing an inorganic or organic monomer (or partial polymer thereof) and which, when used in combination with the other components of the electrolyte, renders the electrolyte solid. Suitable solid polymeric matrices are well known in the art and include solid matrices formed from inorganic polymers, organic polymers or a mixture of organic polymers with inorganic non-polymeric materials. Preferably, the solid polymeric matrix is an organic matrix derived from a solid matrix forming monomer and from partial polymers of a solid matrix forming monomer. See, for example, U.S. Pat. No. 4,925,751, which is incorporated herein.

Alternatively, the solid polymeric matrix can be used in combination with a non-polymeric inorganic matrix. See, for example, U.S. Pat. No. 4,990,413, which is incorporated herein by reference in its entirety. Suitable non-polymeric inorganic materials for use in conjunction with the solid polymeric matrix include, by way of example, β-alumina, silver oxide, lithium iodide, and the like. Suitable inorganic monomers are also disclosed in U.S. Pat. Nos. 4,247,499, 4,388,385, 4,414,607, 4,394,280, 4,432,891, 4,539,276, and 4,557,985 each of which is incorporated herein by reference.

The term "a solid matrix forming monomer" refers to inorganic or organic materials which in monomeric form can be polymerized, preferably in the presence of an inorganic ion salt, and a solvent mixture of an organic carbonate and a glyme compound, to form solid matrices which are suitable for use as solid electrolytes in electrolytic cells. Suitable solid matrix forming monomers are well known in the art and the particular monomer employed is not critical. Preferably, the solid matrix forming monomers have at least c, ne heteroatom capable of forming donor acceptor bonds with inorganic cations (e.g., alkali ions). When polymerized, such compounds form an ionically conductive matrix.

Examples of suitable organic solid matrix forming monomers include, by way of example, propylene oxide, ethyleneimine, ethylene oxide, epichlorohydrin, acryloyl-derivatized polyalkylene oxides (as disclosed in U.S. Pat. No. 4,908,283), urethane acrylate, vinyl sulfonate polyalkylene oxides (as disclosed in U.S. Pat. No. 5,262,253, which patent is incorporated herein by reference in its entirety), and the like as well as mixtures thereof. Examples of suitable inorganic solid matrix forming monomers include, by way of example, phosphazenes and siloxanes. Phosphazene monomers and the resulting polyphosphazene solid matrix are disclosed by Abraham et al., Proc. Int. Power Sources Symp., 34th, pp. 81-83 (1990) and by Abraham et al., J. Electrochemical Society, Vol. 138, No. 4, pp. 92 1-927 (1991).

The term "a partial polymer of a solid matrix forming monomer" refers to solid matrix forming monomers which have been partially polymerized to form reactive oligomers. Partial polymerization may be conducted for the purpose of enhancing the viscosity of the monomer, decreasing the volatility of the monomer, and the like. Partial polymerization is generally permitted so long as the resulting partial polymer can be further polymerized, preferably in the presence of a solvent, such as, a mixture of organic carbonate(s) to form solid polymeric matrices which are suitable for use as solid electrolytes in electrolytic cells.

The term "cured" or "cured product" refers to the treatment of the solid matrix forming monomer or partial polymer thereof under polymerization conditions (including cross-linking) so as to form a solid polymeric matrix. Suitable polymerization conditions are well known in the art and include by way of example, heating the monomer, irradiating the toohomer with UV light, electron beams, and the like. The resulting cured product preferably contains repeating units containing at least one heteroatom such as oxygen or nitrogen which is capable of forming donor acceptor bonds with inorganic cations (alkali ions). Examples of suitable cured products suitable for use in this invention are set forth U.S. Pat. Nos. 4,830,939 and 4,990,4 13 which are incorporated herein by reference in their entirety.

The solid matrix forming monomer or partial polymer can be cured or further cured prior to or after addition of the alkali salt and the electrolytic solvent. For example, a composition comprising requisite amounts of the solid matrix forming monomer, and salt can be applied to a substrate and then cured. Alternatively, the solid matrix forming monomer can be first cured and then dissolved into a suitable volatile solvent. Requisite amounts of the salt can then be added. The mixture is then placed on a substrate and removal of the volatile solvent results in formation of a solid electrolyte. In either case, the resulting solid electrolyte is a homogeneous, single phase product which is maintained upon curing or evaporation, and does not readily separate upon cooling to temperatures below room temperature. Accordingly, the solid electrolyte of this invention does not include a separator as is typical of liquid electrolytes.

The term "salt" refers to any salt, for example, an inorganic salt, which is suitable for use in a solid electrolyte. Representative examples of suitable inorganic ion salts are alkali metal salts of less mobile anions of weak bases having a large anionic radius. Examples of such anions are I⁻, Br⁻, SCN⁻, ClO₄ ⁻, BF₄ ⁻, PF₆ ⁻, AsF₆ ⁻, CF₃ COO⁻, CF₃ SO₃ ⁻, N(SO₂ CF₃)₂₋, and the like. Specific examples of suitable inorganic ion salts include LiClO₄, LiSCN, LiBF₄, LiAsF₆, LiCF₃ SO₃, LiPF₆, (CF₃ SO₂)₂ NLi, (CF₃ SO₂)₃ Cli, NaSCN, and the like. The inorganic ion salt preferably contains at least one cation selected from the group consisting of Li, Na, Cs, Rb, Ag, Cu, Mg and K.

The term "compatible electrolyte solvent" or "electrolytic solvent," or in the context of components of the solid electrolyte, just "solvent," is a low molecular weight organic plasticizer added to the electrolyte and/or the cathode composition, which may also serve the purpose of solvating the inorganic ion salt. The solvent is any compatible, relatively non-volatile, aprotic, relatively polar, solvent. Preferably, these materials have boiling points greater than about 85° C. to simplify manufacture and increase the shelf life of the electrolyte/battery. Typical examples of solvent are mixtures of such materials as propylene carbonate, ethylene carbonate, gamma-butyrolactone, triglyme, tetraglyme, dimethyl-sulfoxide, dioxolane, sulfolane, and the like. A particularly preferred solvent is disclosed in U.S. Pat. 5,262,253, which is incorporated herein solvent is disclosed in U.S. Pat. 5,262,253, which is incorporated herein.

For electrochemical cells where the cathode comprises lithiated cobalt oxides, lithiated manganese oxides, or lithiated nickel oxides, and where the anode comprises carbon, the electrolytic solvent preferably comprises a mixture of ethylene carbonate and dimethyl carbonate. For electrochemical cells where the cathode comprises vanadium oxides, e.g., V₆ O₁₃ and the anode is lithium, the electrolytic solvent preferably comprises a mixture of propylene carbonate and triglyme.

The term "organic carbonate" refers to hydrocarbyl carbonate compounds of no more than about 12 carbon atoms and which do not contain any hydroxyl groups. Preferably, the organic carbonate is a linear aliphatic carbonate and most preferably a cyclic aliphatic carbonate.

Suitable cyclic aliphatic carbonates for use in this invention include 1,3-dioxolan-2-one (ethylene carbonate); 4-methyl-l,3-dioxolan-2-one (propylene carbonate); 4,5-dimethyl-1,3-dioxolan-2-one; 4-ethyl-1,3-dioxolan-2-one; 4,4-dimethyl-1,3-dioxolan-2-one; 4-methyl-5-ethyl- 1,3-dioxolan-2-one; 4,5-diethyl-1,3-dioxolan-2-one; 4,4-diethyl-1,3-dioxolan-2-one; 1,3-dioxan-2-one; 4,4-dimethyl-1,3-dioxan-2-one; 5,5-dimethy-1-1,3-dioxan-2-one; 5-methyl-1,3-dioxan-2-one; 4-methyl-1,3-dioxan-2-one; 5,5-di-ethyl-1,3-dioxan-2-one; 4,6-dimethyl-1,3-dioxan-2-one; 4,4,6-trimethyl-1,3-dioxan-2-one; and spiro (1,3-oxa-2-cyclohexanone-5',5',1',3'-oxa-2'-cyclohexanone).

Several of these cyclic aliphatic carbonates are commercially available such as propylene carbonate and ethylene carbonate. Alternatively, the cyclic aliphatic carbonates can be readily prepared by well known reactions. For example, reaction of phosgene with a suitable alkane-α,β-diol (dihydroxy alkanes having hydroxyl substituents on adjacent carbon atoms) or an alkane-α,γ-diol (dihydroxy alkanes having hydroxyl substituents on carbon atoms in a 1,3 relationship) yields an a cyclic aliphatic carbonate for use within the scope of this invention. See, for instance, U.S. Pat. No. 4,115,206, which is incorporated herein by reference in its entirety.

Likewise, the cyclic aliphatic carbonates useful for this invention may be prepared by transesterification of a suitable alkane-α,β-diol or an alkane-α,γ-diol with, e.g., diethyl carbonate under transesterification conditions. See, for instance, U.S. Pat. Nos. 4,384,115 and 4,423,205 which are incorporated herein by reference in their entirety. Additional suitable cyclic aliphatic carbonates are disclosed in U.S. Pat. No. 4,747,850 which is also incorporated herein by reference in its entirety.

The term "viscosifier" refers to a suitable viscosifier for solid electrolytes. Viscosifiers include conventional viscosifiers such as those known to one of ordinary skill in the art. Suitable viscosifiers include film forming agents well known in the art which include, by way of example, polyethylene oxide, polypropylene oxide, copolymers thereof, and the like, having a number average molecular weight of at least about 100,000, polyvinylpyrrolidone, carboxymethylcellulose, and the like.

The term "novel electrolyte salt" or "electrolyte salt" refers to salts having the structure Formula (I): ##STR7## where A is either ##STR8## where Z is oxygen, --O--, sulfide --SH₂ --, or amine ##STR9## x is 1 to about 10; where R' is selected from the group consisting of an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms, wherein n is independently an integer from 1 to about 5 and R is independently selected from the group consisting of hydrogen, an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms. For R' and R the substituents for the substituted aromatic group include, for example, lower alkyls having 1-3 carbons and halogens (e.g., Cl and Br).

Preferably, R' is an alkyl having 1 to 4 carbon atoms or an unsubstituted or substituted aromatic group having 6 carbon atoms (e.g., a phenyl). Preferably R is independently selected from hydrogen, an alkyl having 1 to 4 carbon atoms or an unsubstituted or substituted aromatic group having 6 carbon atoms (i.e., a phenyl) group;, and most preferably a hydrogen. Preferably x is from 1 to about 5.

As is apparent, the novel electrolyte salt has an anion portion represented by "A" which functions as a counter ion to a metal ion (e.g., Li⁺).

The remainder portion of the novel electrolyte salt functions as the electrolytic solvent.

It is contemplated that the electrolyte salt can replace, in whole or in part, both the salt and electrolytic solvent employed in the solid electrolyte. In this regard, conventional electrolyte compositions typically comprise 5 to about 25% (wt.) inorganic salt and 40 to about 80% (wt.) electrolyte solvent. With the present invention, the amount of novel electrolyte salt used is preferably about 5% to about 90% (wt.), more preferably about 10% to about 80%; and most preferably about 15% to about 60%. The amount of novel electrolyte salt used will depend on the molecular weight of the electrolyte salt which is generally higher than that of the inorganic salts.

The novel electrolyte salt can also be used in combination with the inorganic salt and/or electrolyte solvent that are defined above. As is apparent, when more novel electrolyte salt is employed, less inorganic salt and/or electrolyte solvent are needed. In a preferred embodiment, the electrolyte composition comprises about 40% to about 60% (wt) novel electrolyte salt and from about 30% to about 50% (wt) electrolyte solvent. Some electrolyte solvent may be employed in the electrolyte composition in order to initially process the solid matrix forming monomer or partial polymer since electrolyte solvents may be less expensive than the novel electrolyte salts.

The electrolyte salts of the invention are produced by standard synthetic techniques using commercially available materials. For instance, electrolyte salts that are carboxylic salts can be synthesized by reacting the appropriate carboxylic acid with lithium hydroxide. As an example, an electrolyte salt can be synthesized by first dissolving 17.89 g of 3,6,9 trioxadecanoic acid (available from Aldrich Chem. Co., Inc., Milwaukee, Wis.) in methyl alcohol. To this solution is added a solution consisting of 2.4 g lithium hydroxide dissolved in 50 ml of methyl alcohol. The alcohol is evaporated and the resulting solid is dried.

An example of a sulfonic salt synthesis is shown by the following equations:

    CH.sub.3 OCH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 OH+SOCl.sub.2 →CH.sub.3 OCH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 Cl+HCl+SO.sub.2

Oil(ethylene glycol)methylether

    CH.sub.3 OCH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 Cl+LiSO.sub.3 →CH.sub.3 OCH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 SO.sub.3 Li

The term "electrolytic cell" or "electrochemical cell" refers to a composite containing an anode, a cathode and an ion-conducting electrolyte interposed therebetween.

The term "battery" refers to two or more electrochemical cells electrically interconnected in an appropriate series/parallel arrangement to provide the required operating voltage and current levels.

The anode is typically comprised of a compatible anodic material which is any material which functions as an anode in a solid electrolytic cell. Such compatible anodic materials are well known in the art and include, by way of example, lithium, lithium alloys, such as alloys of lithium with aluminum, mercury, manganese, iron, zinc, intercalation based anodes such as those employing carbon, tungsten oxides, and the like. Particularly preferred anodes include lithium intercalation anodes employing carbon materials such as graphite, cokes, mesocarbons, and the like. Such carbon intercalation based anodes typically include a polymeric binder suitable for forming a bound porous composite having a molecular weight of from about 1,000 to 5,000,000. Examples of suitable polymeric binders include EPDM (ethylene propylene diene termonomer), PVDF (polyvinylidene difluoride), EAA (ethylene acrylic acid copolymer), EVA (ethylene vinyl acetate copolymer), EAA/EVA copolymers, and the like. The anode also may include an electron conducting material such as carbon black.

The cathode is typically comprised of a compatible cathodic material (i.e., insertion compounds) which is any material which functions as a positive pole in a solid electrolytic cell. Such compatible cathodic materials are well known in the art and include, by way of example, transition metal oxides, sulfides, and selenides, including lithiated compounds thereof. Representative materials include cobalt oxides, manganese oxides, molybdenum oxides, vanadium oxides, sulfides of titanium, molybdenum and niobium, the various chromium oxides, copper oxides, lithiated cobalt oxides, e.g., LiCoO₂, lithiated manganese oxides, e.g., LiMn₂ O₄, lithiated nickel oxides, e.g., LiNiO₂, and mixtures thereof.

A preferred method of fabricating an electrochemical cell is described herein. In addition, methods for preparing solid electrochemical cells and batteries are described in the art, for example, in U.S. Pat. Nos. 5,300,373, 5,316,556, 5,346,385, 5,262,253, U.S. patent application Ser. Nos. 07/918,509 filed Jul. 22, 1992; Ser. No. 08/049,212, filed Apr. 19, 1993, and 08/414,874 filed Mar. 31, 1995, which are all incorporated herein in their entirety.

In one preferred embodiment. the cathode is prepared from a cathode paste which comprises from about 35 to 65 weight percent of a compatible cathodic material; from about 1 to 20 weight percent of an electroconductive agent; from about 0 to 20 weight percent of polyethylene oxide having a number average molecular weight of at least 100,000. When the cathode includes V_(6O) ₁₃, the cathode paste preferably further comprises from about 10 to 50 weight percent of solvent comprising a 10:1 to 1:4 (w/w) mixture of an organic carbonate and a glyme. The paste further comprises from about 5 weight percent to about 25 weight percent of a sold matrix forming monomer or partial polymer thereof. Also included is an ion conducting amount of an inorganic ion salt. Generally, the amount of the salt is from about 1 to about 25 weight percent. (All weight percents are based on the total weight of the cathode.)

The electrolyte composition typically comprises from about 5 to about 30 weight percent of the solid polymeric matrix based on the total weight of the electrolyte; preferably froln about 10 to about 20 weight percent.

In a preferred embodiment, the electrolyte composition further comprises a small amount of a film forming agent. Suitable film forming agents are well known in the art and include, by way of example, polyethylene oxide, polypropylene oxide, copolymers thereof, and the like, having a numbered average molecular weight of at least about 100,000. Preferably, the film forming agent is employed in an amount of about 1 to about 10 weight percent and more preferably at about 2.5 weight percent based on the total weight of the electrolyte composition.

The following examples are offered to illustrate the present invention and should not be construed in any way as limiting its scope.

EXAMPLES

The following Examples illustrates a method of how an electrolytic cell could be fabricated.

A solid electrolytic cell is prepared by first preparing a cathodic slurry which is spread onto a current collector. An electrolyte solution containing an electrolyte salt is then placed onto the cathode surface and the cathode slurry and electrolyte solution are simultaneously cured to provide for a solid electrolyte composition. Similarly, an anode composition is placed on a current collector and then an electrolytic solution is placed onto the anode composition and both are cured to form a solid electrolytic composition. Thereafter, the anode and cathode are laminated so that the solid electrolyte composition is situated therebetween to provide for a solid electrolytic cell.

In the following example, the term novel electrolyte salt represents any novel electrolyte salt as defined by formula I, or mixtures thereof. The novel electrolyte salt is used in lieu of inorganic salts (e.g., LiPF₆). In this example, the solid electrolyte also comprises an electrolytic solvent. The specifics of this construction are as follows:

A. The Cathode Current Collector

The cathode current collector employed is a sheet of aluminum foil having a layer of adhesion promoter attached to the surface of the foil which will contact the cathode so as to form a composite having a sheet of aluminum foil, a cathode and a layer of adhesion promoter interposed therebetween. The aluminum foil is preferably an alloy that is identified by either the industry specifications 1235-H19 (99.35% min. A1), or 1145-H19 (99.45 % min. A1), and which is available from All Foils, Inc., Brooklyn Heights, Ohio. (Alternatively, aluminum mesh can be used as the current collector.) The adhesion promoter layer is prepared as a dispersed colloidal solution in one of two methods. The first preparation of this colloidal solution for this example is as follows:

8.44 parts by weight of carbon powder (Shawinigan Black™--available from Chevron Chemical Company, San Ramon, Calif.)

33.76 parts by weight of a 25 weight percent solution of polyacrylic acid (a reported average molecular weight of about 90,000, commercially available from Aldrich Chemical Company contains about 84.4 grams polyacrylic acid and 253.2 grams water)

57.80 parts by weight of isopropanol

In a preferred embodiment of the first method, an additional amount of water, e.g., 2-3 weight percent water based on the total weight of the colloidal solution, is incorporated to enhance coatability. Also, about 1 weight percent methyl ethyl ketone is added to the composition to enhance wettability of the aluminum.

The carbon powder and isopropanol are combined with mixing in a conventional high shear colloid mill mixer (Ebenbach-type colloid mill) until the carbon is uniformly dispersed and the carbon particle size is smaller than 10 μm. At this point, the 25 weight percent solution of polyacrylic acid is added to the mixer and further mixed for approximately 15 minutes. The resulting mixture is pumped to the coating head and applied by a reverse Gravure roller onto a sheet of aluminum foil about 9 in. (22.86 cm) wide and allout 0.0005 in. (0.00127 cm) to about 0.001 in. (0.00254 cm) thick. After application, the solvent is evaporated by placing the mixture/foil into a conventional oven. After evaporation, an electrically-conducting adhesion-promoter layer of about 4-6 μm in thickness is formed. The aluminum foil is then cut to about 8 in. (20.32 cm) wide by removing approximately 1/2 in. (1.27 cm) from the sides with a conventional slitter so as to remove any uneven edges; the foil can then be further cut to the desired size.

The second preparation of this colloidal solution comprises mixing 25 lbs (11.35 kg) of carbon powder (Shawinigan Black™) with 100 lbs (45.4 kg) of a 25 weight percent solution of polyacrylic acid (average molecular weight of about 240,000, commercially available from BF Goodrich, Cleveland, Ohio, as Good-Rite K702--contains about 25 lbs (11.35 kg) polyacrylic acid and 75 lbs (34.05 kg) water) and with 18.5 lbs (8.399 kg) of isopropanol. Stirring is done in a 30 gallon (113.55 liters) polyethylene drum with a gear-motor mixer (e.g., Lighting Labmaster Mixer, model XJ-43, available from Cole-Parmer Instruments Co., Niles, Ill.) at 720 rpm with two 5 in. (12.7 cm) diameter A310-type propellers mounted on a single shaft. This wets down the carbon and eliminates any further dust problem. The resulting weight of the mixture is 143.5 lbs (65.149 kg) and contains some "lumps."

The mixture is then further mixed with an ink mill which consists of three steel rollers almost in contact with each other, turning at 275,300, and 325 rpms respectively. This high shear operation allows particles that are sufficiently small to pass directly through the rollers. Those that do not pass through the rollers continue to mix in the ink mill until they are small enough to pass through these rollers. When the mixing is complete, the carbon powder is completely dispersed. A Hegman fineness of grind gauge (available from Paul N. Gardner Co., Pompano Beach, Fla) indicates that the particles are 4-6 μm with the occasional 12.5 μm particles. The mixture can be stored for well over 1 month without the carbon settling out or reagglomerating.

When this composition is to be used to coat the current collector, an additional 55.5 lbs (25.197 kg) of isopropanol is mixed into the composition working with 5 gallon (18.925 l) batches in a plastic pail using an air powered shaft mixer (Dayton model 42231 available from Granger Supply Co., San Jose, Calif.) with a 4 in. (10.16 cm) diameter Jiffy-Mixer brand impeller (such as an impeller available as Catalog No. G-04541-20 from Cole Parmer Instrument Co., Niles, Illinois). Then, it is gear pumped through a 25 μm cloth filter (e.g., So-Clean Filter Systems, American Felt and Filter Company, Newburgh, N.Y.) and coated as described above.

B. The Cathode

The cathode is prepared from a cathodic slurry which, in turn, is prepared from a cathode powder as follows:

i. Cathode Powder

The cathode powder is prepared by combining 94.1±1.1 weight percent LiMn₂ O₄ and 5.9±1.1 weight percent of carbon (Shawinigan Black™). About 100 grams of the resulting mixture is placed into a grinding machine (Attritor Model S-1 available from Union Process, Akron, Ohio) and ground for 30 minutes at 150 rpm Afterwards, the resulting mixture is passed through a 200 mesh screen and then vacuum dried at 60° C. to produce a cathode powder with a water content of less than about 1000 ppm and preferably less than about 300 ppm.

ii. Cathode Slurry

A cathode slurry is prepared by combining sufficient cathode powder to provide for a final product having about 51.7 weight percent LiMn₂ O₄. The slurry contains the following (in approximate weight percent):

    ______________________________________                                         LiMn.sub.2 O.sub.4      51.744%                                                Carbon                  6.456%                                                 EPDM (ethylene propylene                                                                               1.8%                                                   diene monomer)                                                                 Xylene                  40.0%                                                                          100%                                                   ______________________________________                                    

The method of preparing 100 grams of the cathode slurry is as follows:

1.8 grams of EPDM (Mooney viscosity of 26±5 and available as VISTALON™ 2504 from Exxon Chemical Co., Houston, Tex.) is mixed in 16.2 grams of xylene to form a 10.0% (wt.) EPDM solution. The temperature is maintained at between 40°--45° C. as the EPDM is added. The solution is preferably filtered through a 20 micron filter cartridge.

An amount of carbon powder sufficient to provide 51.744 grams of LiMn₂ O₄ per 100 grams of cathode slurry and a sufficient amount of carbon (Shawinigan Black™) to provide 6.456 grams of total carbon per 100 grams of slurry are mixed in a double planetary mixer where the blend is stirred at 7.5 Hz and 25° C. The above EPDM-xylene solution is passed through 4Å molecular sieves and then added to the LiMn₂ O₄ and carbon blend under vacuum mixing over a 5 minute period during which time an additional 23.8 grams of xylene are added. Afterwards, the mixing speed is increased from 7.5 to 20 Hz and maintained for another 5 minutes. Thereafter, the temperature of the mixture is gradually raised to 85° C. over about a 45 minute period and maintained at the elevated temperature for about 30 minutes. Next, the mixing speed is decreased to about 1 Hz and subsequently the temperature of the mixture is allowed to decrease gradually to about 45° C. over about a 30 minute period. Finally, the mixture is mixed for 5 minutes at this temperature.

The extruded cathode slurry is then spread to a substantially uniform thickness of about 25-200 μm, more preferably 50-100/xm, and most preferably about 100 μm, over the current collector by a doctor blade, Meyer-rod, or by reverse roll coating. The cathode slurry/current collector is heated to remove the xylene.

C. Electrolyte

36.26 grams of propylene carbonate, 36.26 grams of ethylene carbonate, and 17.24 grams of urethane acrylate are combined at room temperature until homogeneous. The resulting solution is optionally passed through a column of 4Å molecular sieves to remove water and then the recovered solution is mixed at room temperature until homogeneous. If necessary, the ethylene carbonate can first be dissolved in propylene carbonate with heat.

At this point, 1.47 grams of polyethylene oxide film forming agent having a number average molecular weight of about 600,000 (available as Polyox WSR-205 from Union Carbide Chemicals and Plastics, Danbury, Conn.) is added to the above solution and then dispersed while stirring with a magnetic stirrer over a period of about 60-120 minutes. After dispersion, the solution is heated to between 60° and 65° C. with stirring until the film forming agent is dissolved. A thermocouple is placed at the edge of the vortex created by the magnetic stirrer to monitor solution temperature. The solution is cooled to a temperature of less than 48° C. and then 8.77 grams of the novel electrolyte salt are added to the solution over a 120 minute period while thoroughly mixing to ensure a substantially uniform temperature profile throughout the solution. Cooling is applied as necessary to maintain the temperature of the solution at less than 48° C.

In one optional embodiment, the polyethylene oxide film forming agent is added to the solution via a mini-sieve, such as a 25 mesh mini-sieve that is commercially available as Order No. 57333-965 from VWR Scientific, San Francisco, Calif.

The resulting solution contains the following, in approximate weight percent based on the total weight of the electrolyte solution (100 g):

    ______________________________________                                         Propylene Carbonate     36.26%                                                 Ethylene Carbonate      36.26%                                                 urathane acrylate       17.24%                                                 novel electrolyte salt  8.77%                                                  PEO Film Forming Agent  1.47%                                                  Total                   100%                                                   ______________________________________                                    

This solution is then degassed to provide for an electrolyte solution wherein little, if any, of the electrolyte salt decomposes.

Optionally, the above solution which contains the prepolymer, the film forming agent, the electrolytic solvents and the electrolyte salt, is filtered to remove any solid particles or gels remaining in the solution. One suitable filter device is a sintered stainless steel screen having a pore size between 1 and 50 μm at 100% efficiency.

In an alternative embodiment, the electrolyte is prepared by the following steps using the same above described electrolyte components:

1. Check the moisture level of the urethane acrylate. If the moisture level is less than 100 ppm water, proceed to step 2. If not, then first dissolve the urethane acrylate at room temperature, <30° C., in the propylene carbonate and ethylene carbonate and dry the solution over 4A molecular sieves (Grade 514, 8-12 Mesh from Schoofs Inc., Moraga, Calif.) and then proceed to step 4.

2. Dry the propylene carbonate and ethylene carbonate over 4Å molecular sieves (Grade 514, 8-12 Mesh from Schoofs Inc., Moraga, Calif.).

3. At room temperature, <30° C., add the urethane acrylate to the solvent prepared in step 2. Stir until the resin is completely dissolved. The solution should be clear and colorless.

4. Dry and optionally sift the polyethylene oxide film forming agent through a 25 mesh mini-sieve commercially available as Order No. 57333-965 from VWR Scientific, San Francisco, Calif. While stirring add the dried and pre-sifted polyethylene oxide film forming agent slowly to the solution. The polyethylene oxide film forming agent should be sifted into the center of the vortex formed by the stirring means at a controlled rate to avoid agglomerate formation. Addition of the polyethylene oxide film forming agent should be dispersive and, during addition, the temperature should be maintained at room temperature (<30° C.).

5. After final addition of the polyethylene oxide film forming agent, stir to ensure that the film forming agent is substantially dispersed.

6. Heat the mixture to 68° to 75° C. and stir until the film forming agent has melted and the solution has become transparent. Optionally, in this step, the mixture is heated to 65° to 68° C.

7. Cool the solution produced in step 6 and when the temperature of the solution reaches 40° C., add the electrolyte salt very slowly making sure that the maximum temperature does not exceed 55° C. and preferably does not exceed about 40° C.

8. Following the addition of the electrolyte salt, the solution is stirred and degassed. The electrolyte solution is allowed to cool before usage.

9. Optionally, filter the solution through a sintered stainless steel screen having a pore size between 1 and 50 μm at 100% efficiency.

At all times, the temperature of the solution should be monitored with a thermocouple which should be placed in the vortex formed by the mixer.

Afterwards, the electrolyte mixture is coated by a slot die coater or a reverse roll flexographic coater to a thickness of about 25-50 μm onto the surface of the dried cathode slurry described above.

D. The Anode Current Collector

The anode current collector employed is a sheet of copper foil, about 0.33 mils (8.5 μm) to 0.5 mils (12.7 μm) thick, having a layer of adhesion promoter attached to the surface of the foil which will contact the anode so as to form a composite having a sheet of copper foil, an anode and a layer of adhesion promoter interposed therebetween. (Alternatively, copper mesh can be used as the current collector.)

The same adhesion promoter composition used with the cathode is employed with the anode.

E. The Anode

The anode is prepared from an anodic slurry which, in turn, is prepared from an anode powder as follows:

i. Anode Powder

The anode powder is prepared by combining about 93.81 weight percent of Mitsubishi Gas Carbon™ (a coke-like material) (Mitsubishi Petroleum Co. Ltd, Tokyo, Japan) and about 6.19 weight percent of carbon (Shawinigan Black™). About 100 grams of the resulting mixture is placed into a grinding machine (Attritor Model S-1 available from Union Process, Akron, Ohio) and ground for 30 minutes at 150 rpm Afterwards, the resulting mixture is passed through a 200 mesh screen and then vacuum dried at 60° C. to produce an anode powder with a water content of less than about 1000 ppm and preferably less than about 300 ppm.

ii. Anode Slurry

An anode slurry is prepared by combining sufficient anode powder to provide for a final product having about 54.6 weight percent of the Mitsubishi Gas Carbon. The slurry contains the following (in approximate weight percent):

    ______________________________________                                         Mitsubishi Gas Carbon   54.6%                                                  Carbon                  3.6%                                                   EPDM (ethylene propylene                                                                               1.8%                                                   diene monomer)                                                                 Xylene                  40.0%                                                                          100%                                                   ______________________________________                                    

The method of preparing 100 grams of the anode slurry is as follows:

1.8 grams of EPDM (VISTALON™ 2504) is mixed in 16.2 grams of xylene to form a 10.0% (wt.) EPDM solution. The temperature is maintained at between 40°-45° C. as the EPDM is added to the xylene. The solution is preferably filtered through a 20 micron filter cartridge.

An amount of anode powder sufficient to provide 54.6 grams of Mitsubishi Gas Carbon per 100 grams of anode slurry and a sufficient amount of carbon (Shawinigan Black ™) to provide 3.6 grams of total carbon per 100 grams of slurry are mixed in a double planetary mixer where the blend is stirred at 7.5 Hz and 25° C. The above EPDM-xylene solution is passed through 4A molecular sieves and then added to the Gas Carbon and carbon blend under vacuum mixing over a 5 minute period during which time an additional 23.8 grams of xylene are added. Afterwards, the mixing speed is increased from 7.5 to 20 Hz and maintained for another 5 minutes. Thereafter, the temperature of the mixture is gradually raised to 85 ° C. over about a 45 minute period and maintained at the elevated temperature for about 30 minutes. Next, the mixing speed is decreased to about 1 Hz and subsequently the temperature of the mixture is allowed to decrease gradually to about 45° C. over about a 30 minute period. Finally, the mixture is mixed for 5 minutes at this temperature.

The so-prepared anode slurry can be placed onto the adhesion layer of the current collector by coating a layer of the slurry having a substantially uniform thickness of about 25-200 μm, more preferably 50-100 μm, and most preferably about 50 μm, over the current collector by a doctor blade, Meyer-rod, or by reverse roll coating. The anode slurry/current collector is then heated to remove the xylene.

Afterwards, an electrolyte mixture is coated by a slot die coater or a reverse roll flexographic coater to a thickness of about 25-50 μm onto the surface of the dried anode slurry described above.

F. The Solid Electrolytic Cell

A sheet comprising a solid battery is prepared by laminating the electrolyte/anode composite with the electrolyte/cathode composite so that the electrolyte is positioned between the anode and cathode. Lamination is accomplished by minimal pressure.

Although only preferred embodiments of the invention are specifically disclosed and described above, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention. 

What is claimed is:
 1. A solid electrolyte which comprises:a solid polymeric matrix; and an electrolyte composition comprising an effective amount of an electrolyte salt having the structure: ##STR10## where A is either ##STR11## where Z is oxygen, --O--, sulfide --SH₂ --, or amine ##STR12## x is 1 to about 10; where R.sup. is selected from the group consisting of an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about carbon atoms, and wherein n is independently an integer from 1 to about 5 and R is independently selected from the group consisting of hydrogen, an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms provided that when A is --SO₃ --, Z is sulfide or amine.
 2. The solid electrolyte of claim 1, further comprising an electrolyte solvent.
 3. The solid electrolyte of claim 2 wherein said electrolyte composition comprises about 40% to about 60% (wt) of said electrolyte salt and comprises about 30% to about 50% (wt) of said electrolyte solvent.
 4. The solid electrolyte of claim 1, wherein A is --SO₃ -- and Z is sulfide or amine.
 5. The solid electrolyte of claim 4 wherein the electrolyte salt comprises about 15% to about 60% (wt) of the electrolyte composition.
 6. The solid electrolyte of claim 5 wherein R' is selected from the group consisting of an alkyl having 1 to 4 carbons and unsubstituted or substituted phenyl group, and R is independently selected from the group consisting of hydrogen, an alkyl having 1 to 4 carbons, and an unsubstituted or substituted phenyl group.
 7. The solid electrolyte of claim 1 wherein the electrolyte salt comprises about 15% to about 60% (wt) of the electrolyte composition and A is ##STR13##
 8. The solid electrolyte of claim 7 wherein R' is selected from the group consisting of an alkyl having 1 to 4 carbons and unsubstituted or substituted phenyl group, and R is independently selected from the group consisting of hydrogen, an alkyl having 1 to 4 carbons, and an unsubstituted or substituted phenyl group.
 9. The solid electrolyte of claim 1 wherein Z is sulfide or amine.
 10. An electrolytic cell which comprises:an anode; a cathode; and interposed therebetween a solid electrolyte which comprises: a solid polymeric matrix; and an electrolyte composition comprising an effective amount of an electrolyte salt having the structure: ##STR14## where A is either ##STR15## where Z is oxygen, --O--, sulfide-SH₂ --, or amine ##STR16## x is 1 to about 10; where R¹ is selected from the group consisting of an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms, and wherein n is independently an integer from 1 to about 5 and R is independently selected from the group consisting of hydrogen, an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms provided that when A is --SO₃ --, Z is sulfide or amine.
 11. The electrolytic cell of claim 10, wherein the solid electrolyte further comprises an electrolyte solvent.
 12. The electrolytic cell of claim 10 wherein said elecrolyte composition comprises about 40% to about 60% (wt) of said electrolyte salt and comprises about 30% to about 50% (wt) of said electrolyte solvent.
 13. The electrolytic cell of claim 10, wherein A is --SO₃ -- and Z is sulfide or amine.
 14. The electrolytic cell of claim 10, wherein the electrolyte salt comprises about 15% to about 60% (wt) of the electrolyte composition.
 15. The electrolytic cell of claim 14 wherein R' is selected from the group consisting of an alkyl having 1 to 4 carbons and unsubstituted or substituted phenyl group, and R is independently selected from the group consisting of hydrogen, an alkyl having 1 to 4 carbons, and an unsubstituted or substituted phenyl group.
 16. The electrolytic cell of claim 10 wherein the electrolyte salt comprises about 15 % to about 60% (wt) of the electrolyte composition and A is ##STR17##
 17. The electrolytic cell of claim 16 wherein R' is selected from the group consisting of an alkyl having 1 to 4 carbons and unsubstituted or substituted phenyl group and R is independently selected from the group consisting of hydrogen, an alkyl having 1 to 4 carbons, and an unsubstituted or substituted phenyl group.
 18. The electrolytic cell of claim 10 wherein the anode is an intercalation based anode comprising carbon.
 19. The electrolytic cell of claim 18 wherein the cathode is selected from the group consisting of vanadium oxides, lithiated cobalt oxides, lithiated manganese oxides, and lithiated nickel oxides.
 20. The electrolytic cell of claim 10 wherein the cathode is selected from the group consisting of vanadium oxides, lithiated cobalt oxides, lithiated manganese oxides, and lithiated nickel oxides.
 21. The electrolytic cell of claim 10 wherein Z is sulfide or amine.
 22. A method of fabricating an electrochemical cell comprising the steps of:providing an anode; providing a cathode; andforming a solid electrolyte between the anode and the cathode, wherein the solid electrolyte comprises: a solid polymeric matrix; and an electrolyte composition comprising an effective amount of an electrolyte salt having the structure: ##STR18## where A is either ##STR19## where Z is oxygen, --O--, sulfide --SH₂ --, or amine ##STR20## x is 1 to about 10; where R¹ is selected from the group consisting of an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms, and wherein n is independently an integer from 1 to about 5 and R is independently selected from the group consisting of hydrogen, an alkyl group having 1 to about 5 carbon atoms, and an unsubstituted or substituted aromatic group having from 6 to about 11 carbon atoms provided that when A is --SO₃ -- Z is the sulfide or amine.
 23. The method of claim 22 wherein Z is the sulfide or amine. 